Gas-Fired Heater with Carbon Dioxide Detector

ABSTRACT

A portable gas-fired heater comprising a housing, a burner assembly, and a carbon dioxide detector system. The housing is adapted to at least partially enclose a fuel source. The burner assembly is enclosed by the housing.

TECHNICAL FIELD

Provided is a gas-fired heater comprising a carbon dioxide detector.More particularly, provided is gas-fired heater comprising a carbondioxide detector-based safety shut-off valve.

BACKGROUND

Gas-fired portable heaters are well known in the art and are used inmultiple environments. The heater typically includes a housing having achamber. The housing has an inlet for receiving air into the chamber.Gas is introduced into the chamber to be mixed with the air in order tocomplete combustion and provide an infrared heating surface. A plenumdirects the heat toward a mesh screen and distributes it over thesurface thereof.

The use of such heaters is strictly regulated for outdoor only use dueto the emission of carbon monoxide and other potentially harmfulcombustion products. Prior designs in existing portable units aresubject to a wide variety of problems. The prior designs are not safe orcertified to operate in small recreational enclosures such as tents,truck-caps, fishing huts, trailers, vans, etc. There are many reasonswhy the devices found in the prior art are not adequate to perform insuch environments. Some previous designs do not have the ability to meetsafety regulations regarding combustion requirements at a high and lowfiring condition and at a reduced pressure. Some designs do not possessan oxygen depletion system (“ODS”). Some designs do not measure orrespond to undesirable carbon dioxide levels. These shortcomings haveprevented many portable heaters from adequately performing in smallrecreational and temporary work enclosures.

Therefore, it remains desirable to provide a portable gas-fired heatercapable of performing safely in small recreational enclosures andtemporary work enclosures.

SUMMARY

Provided is a portable gas-fired heater comprising a housing, a burnerassembly, and a carbon dioxide detector system. The housing is adaptedto at least partially enclose a fuel source. The burner assembly isenclosed by said housing.

Provided is a portable gas-fired infrared heater comprising a housing, aregulator, burner assembly, a radiant surface, a plenum chamber, and acarbon dioxide detector system. The housing comprises a handle adaptedfor transporting the heater and an air inlet. The burner assembly ismounted within the housing. The burner assembly comprises a fuel valveadapted to control communication with a fuel source, and a venturi formixing air from the air inlet and fuel from the fuel valve into afuel-air mixture. The radiant surface is recessed into the housing. Theradiant surface is disposed at an angle to vertical and comprises a rearface. The plenum chamber is adjacent to the radiant surface, is incommunication with said radiant surface, and is adapted to distributesaid fuel-air mixture onto the rear face of the radiant surface. Thecarbon dioxide detector system is adapted to shut off the fuel valve inresponse to detection of a predetermined level of carbon dioxide.

Provided is a portable gas-fired radiant heater comprising a housing, afuel source, a fuel connection fitting, an air inlet, a burner assembly,a radiant surface, and an automatic shutoff mechanism. The burnerassembly is mounted within the housing. The burner assembly comprises afuel valve adapted to control communication with said fuel source. Theradiant surface is in the housing. The radiant surface is adapted tofunction as a combustion site. The automatic shutoff mechanism isoperatively associated with the burner assembly for shutting off thefuel valve in response to a detection of a predetermined level of carbondioxide.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective cross-sectional view of one embodiment of aheater assembly;

FIG. 2 is a longitudinal cross-sectional view of one embodiment of aheater assembly;

FIG. 3 is an enlarged elevational view of one embodiment of athermocouple, spark igniter, and pilot tube assembly;

FIG. 4 is a perspective view of one embodiment of a heater takengenerally from the front and left-hand side;

FIG. 5 is a perspective view of one embodiment of a heater takengenerally from the front and right-hand side;

FIG. 6 is a perspective view of one embodiment of a heater takengenerally from the rear and right-hand side;

FIG. 7 is a perspective view of one embodiment of a heater takengenerally from the rear and left-hand side;

FIG. 8 is a perspective elevational view of one embodiment of a heater;

FIG. 9 is a bottom view of one embodiment of a portable heater;

FIG. 10 is a side elevational view of one embodiment of a portableheater;

FIG. 11 is a side elevational view of one embodiment of a portableheater;

FIG. 12 is a rear elevational view of one embodiment of a portableheater;

FIG. 13 is a front elevational view of one embodiment of a portableheater;

FIG. 14 is a top view of one embodiment of a portable heater;

FIG. 15 is a perspective view of one embodiment of a portable heater;

FIG. 16 is a perspective view of one embodiment of a portable heater;

FIG. 17 is a top perspective exploded view of one embodiment of aportable heater;

FIG. 18 is a perspective view of one embodiment of a portable heater;

FIG. 19 is a perspective view of one embodiment of a portable heater;

FIG. 20 is a top elevational view of one embodiment of a portable heaterwith handle and front grill removed;

FIG. 21 is a front elevational view of one embodiment of a portableheater of FIG. 20 showing a fuel source in ghost lines;

FIG. 22 is a top elevational view of one embodiment of a portableheater;

FIG. 23 is a front elevational view of FIG. 22;

FIG. 24 is a top elevational view of one embodiment of a portable heaterwith handle and front grill removed;

FIG. 25 is a front elevational view of FIG. 24.

FIG. 26 is a rear perspective view with rear and side panels removed;and

FIG. 27 is a bottom perspective view illustrating a remote LP gas supplyhose.

DETAILED DESCRIPTION

Referring now to the drawings wherein the showings are only for purposesof illustrating certain embodiments of the heater, and not for purposesof limiting same, the Figures show a portable heating device A adaptedfor use in small enclosed environments.

Referring, without limitation, to the embodiment depicted in FIGS. 1-27,the portable heater A includes a housing 10 having a front face 12, arear face 14, and two sides 16, 18. The housing 10 may be manufacturedto have smooth contours to prevent snagging or catching of things suchas clothing, fabric, etc. A stepped recess or external cavity may beformed in a corner region of the left side 16 of the housing 10 forsupporting a control knob or temperature controller 20. A recessprovides protection against inadvertent contact and accidental changingof the temperature. In certain embodiments, the temperature controller20 has four positions: off, pilot, low, and high (not shown) In certainembodiments, the temperature controller 20 has continuously variablepositions for infinitely variable heating. A controller may incorporatea piezo spark igniter integral to controller stem rotation.

In certain embodiments, the heater A is supported by two elongated legs24 a, 24 b laterally disposed along the outboard edges of the rear face14 and front face 12 respectively. The legs 24 a , 24 b may be groovedto provide a friction surface to contact a supporting surface and mayextend over the entire width of the housing to provide a wide“footprint” and stable support area for the heater. In anotherembodiment (not shown), additional legs extending front to rear areprovided beneath legs 24 a, 24 b to increase air flow beneath theheater. A handle 26 extends from the top of the heater. In certainembodiments the handle 26 forms an angle directed away from the frontface 12. In certain embodiments this angle is approximately 15°. Anangle allows the handle 26 to remain cool for handling by a user as theangled orientation of the handle 26 protects the user's hand from heatexiting the top of the heater A while the user transports the heater A.In the alternative, a non-angled handle (not shown) provides a gripsurface for carriage of the heater. The handle 26 may optionally begrooved to provide an enhanced gripping surface for the user.

In certain embodiments, a shield or metal grid 30 is attached to thefront face 12 of the heater to provide protection to the heatercomponents. In addition, the shield prevents accidental contact with thehot portions of the heater front face 12. The shield may be made fromelongated wire or metal strips. In certain embodiments, peripheralpieces of the shield may be received in openings 32 in the housing tosecure the shield to the heater. In certain embodiments, keyholeopenings or recesses 34 a , 34 b are located on the upper portion of theback face 14 of the heater allowing the user to hang the heater.

The air inlet 40 may be any opening that adequately provides air inflow.In certain embodiments, an opening or air inlet 40 is disposed on alower portion of the front face 12 of the heater for receiving andfiltering air drawn into the housing. In certain embodiments the airinlet is formed from a series of elongated slits 42 spaced across thehousing beneath the shield.

In certain embodiments, an LP (“Liquefied Petroleum” or “LiquefiedPropane”) gas supply 50 is secured to and partially enclosed by thehousing 10 (See FIGS. 5 and 6). An LP gas supply 50 may be a removablecanister or propane tank that can be replaced by a new tank or removed,refilled, and re-installed in the housing. In certain embodiments, an LPgas supply comprises a one pound propane cylinder. In certainembodiments, a dome 52 protrudes from the side 18 of the housing 10 andpartially encloses the gas supply tank 50. The dome acts as a protectiveshroud to cover the interconnection of the tank with the housing. Incertain embodiments, an LP gas supply comprises a twenty pound propanetank. Without limitation, a twenty pound propane tank may be connectedto the heater by length hose so that the tank can be located away fromthe heated region. Without limitation, a hose connected propane tank canbe positioned outside a tent, cabin, fishing shanty garage, etc. whilethe heater is located within the structure.

The gas supply 50 is connected to a regulator which connects to a valveand orifice 56 (See FIG. 1) which is selectively adjustable between openand closed positions, access being provided to the regulator throughwindow opening 58 for remote LP gas supply hose tightening and leakchecking (see FIG. 6). Optionally the LP gas supply hose 130 withconnector fittings 132 , 134 is stored underneath the unit withinreceptacles 136 in combination with side ledges 138 illustrated in FIG.27. It is recognized that the LP couplings may be “quick connects” whenthe supply pressure is already regulated to about 11″ water column. Inthis embodiment, the quick-coupler hose is integral to the heater anddownstream from heater regulator(s) but before the control valve tofacilitate connection to a regulated hose supply from an external fuelsource such as a 20 pound cylinder. Similarly, the regulated fuel supply(11″ water column) could originate from a self-contained system as in arecreational vehicle. The quick-coupler hose connection wouldincorporate positive fuel shut-off in both male and female connectioncomponents to prevent fuel escape when disconnected.

Referring again to FIGS. 1 and 2, a burner venturi 60 is enclosed withinthe housing 10 and operates to mix oxygen and propane for combustion.The burner venturi 60 has a hollow generally cylindrical body 62 and atapered mouth 64 having a wider diameter than the body 62. The burnerventuri is disposed at an angle a relative to the longitudinal axis ofthe heater A. The mouth 64 of the burner venturi is positioned onapproximately the same axial plane as the air inlet 40 and thecylindrical body 62 extends upwardly from the mouth 64. The orifice 56which is attached to the gas supply 50 is located directly beneath themouth 64 of the burner venturi 60.

Also located within the housing A is a generally planar radiant surface70 disposed at an angle a relative to the longitudinal axis of theheater. A rear face of the radiant surface is in communication with acavity or plenum chamber 72. The burner plenum receives the air/gasmixture from the venturi and distributes the mixture over and throughthe rear face of the radiant surface. Thus, in operation, the orifice56, attached to the gas supply, is opened releasing a fuel gas such aspropane into the mouth 64 of the burner venturi 60. Associated with theorifice is a regulator that reduces the delivery pressure of the fuelgas from the tank (rated up to 150 psi) to eleven inches of water columnin one stage. Thus, this portable heater operates at a significantlylower pressure than existing commercially available units. The stream ofgas exiting the orifice 56 creates a vacuum effect drawing air from theair inlet 40 into the mouth 64 of the burner venturi. Propane and airare thoroughly mixed in the burner venturi 60 and plenum 72 in order toachieve complete combustion and produce a clean burning infrared heatingsurface. The mixture of oxygen and propane travels upward through thecylindrical body 62 of the burner venturi 60 until reaching the plenumchamber 72. To prevent the mixture of propane and oxygen fromimmediately exiting the plenum chamber 72, a solid baffle 76 is providedwhich forces the air/gas mixture downward into communication with therear face of the radiant surface.

The radiant surface may be a burner tile or a multi-ply screens (notshown) that define a plurality of small openings which permit combustionof the air/gas mixture as it passes therethrough. A means is providedfor initially sparking or igniting the mixture at the radiant surface.In the present invention a container 80 houses the pilot 82 and theigniter 84 (see FIG. 3) which provides the initial sparking. It will beappreciated that any conventional means for initially sparking origniting the mixture can be utilized. Combustion of the air/gas mixtureis maintained and reaches elevated temperatures of approximately 1200°F. The heater shown in the drawings with one propane cylinder is ratedat a minimum 4000 BTUs and a maximum 9000 BTUs at eleven inches watercolumn pressure. Other ratings are also potential alternatives,including up to 20,000 to 25,000 BTU models when more than one propanecylinder and associated burner assemblies are utilized.

A reflector 90 extends outwardly from the top of the burner plenum 72 atan angle directed toward the top portion of the front face 12 of thehousing 10. The natural convective upward path of the combustionproducts leads the combustion products into contact with the reflector90. The reflector 90, in addition to directing the radiant energy outputfrom the heater toward the front surface of the housing, also acts as adeflector and reduces the temperature of the combustion products exitingthe heater which greatly reduces the chance for ignition of acombustible material if it comes into contact with the heater. An outlet92 is disposed near the top of the housing 10 allowing warm air to mixwith combustion products and exit the device after contacting thereflector 90. In addition, a deflector 95 is disposed on the top offront face 12 which reduces the temperature of the combustion productsexiting the heater which greatly reduces the chance for ignition of acombustible material if it comes into contact with the heater A.

In addition, there is an outlet or grate 94 disposed rearward of outlet92 that communicates with the interior of the housing. It provides acontinuous flow path for air (that does not enter the venturi) to flowfrom the inlet 40 around the rear of the plenum chamber and exit thehousing rearward of the deflector. This enhances the chimney effect asdescribed above since a large amount of ambient air is drawn into thehousing, a portion used for combustion purposes and the remainderconvects upwardly along the rear of the plenum and the deflector to exitvia the openings 94 The air inlet 40 of the present invention isdesigned to encourage air flow along the back of the hot burner plenum72, advantageously resulting in an increased velocity of air flow to theburner venturi, as well as cooling the rear housing 10. As the burnerventuri 60 is heated, the thermal convection properties urge the air/gasmixture through the upwardly angled burner venturi 60 creating a chimneytype effect. The chimney effect created by the present inventionincreases the fresh air flow velocity into the burner venturi, enablingthe pressure from the gas supply 50 to be reduced, yet burn efficientlyon high or low settings.

In certain embodiments the heater may comprise carbon dioxide detectorsystem. A carbon dioxide detector system comprises a carbon dioxidedetector. A carbon dioxide detector system comprises a PC board. Acarbon dioxide detector system comprises a power supply battery. Withoutlimitation, the batteries comprising a power supply may comprise two (2)“D” Cell batteries or any combination of quantity and different cellsizes.

A carbon dioxide detector system provides a safety function by operatingto shut off the fuel supply at a some predetermined operational state orgaseous range (%). In certain embodiments, the carbon dioxide detectorsystem performs the following operations: 1) produce atmospheric carbondioxide data by measuring the carbon dioxide in the atmosphere using thecarbon dioxide detector 2) produce atmospheric oxygen data bycalculating an atmospheric oxygen level from the atmospheric carbondioxide data using the computer, 3) compare atmospheric oxygen data to apredetermined atmospheric oxygen level, 4) If the atmospheric oxygendata is less than the predetermined atmospheric oxygen level,discontinue a signal output (“open valve signal”) necessary to keep anormally closed safety valve open. In the described embodiment, if theatmospheric oxygen data is less than the predetermined atmosphericoxygen level the safety valve is closed due to lack of the open valvesignal.

The predetermined atmospheric oxygen level may be any oxygen level. Incertain embodiments the predetermined atmospheric oxygen level is atleast 18%.

In certain embodiments, a carbon dioxide detector system safetyinterlock functionality is included whereby interruption of thefunctionality of a carbon dioxide detector system results in the safetyvalve being closed due to removal of a signal necessary to keep it open.In certain embodiments, if the carbon dioxide detector system isde-energized by removal, disruption, or failure of the power supplyelement, the open valve signal will be discontinued, thereby closing thesafety valve.

In certain embodiments a carbon dioxide detector system may operate inconjunction with a standing pilot and safety valve. Without limitation,in certain heaters comprising a carbon dioxide detector system operablein conjunction with a standing pilot and safety valve, a flame from thestanding pilot is controlled by the carbon dioxide detector system. Whenthe atmospheric oxygen data is equal to or above the predeterminedatmospheric oxygen level, the carbon dioxide detector system maintainsthe flame in a state to heat a thermocouple to produce the open valvesignal needed to keep the safety valve open. When the atmospheric oxygendata is less than the predetermined atmospheric oxygen level, the carbondioxide detector system will interrupt the open valve signal.Interruption of the open valve signal may be by opening a circuit ordiscontinuation of the signal production.

FIG. 17 illustrates yet another embodiment of the invention in whichimproved air flow is effected through heater unit A by the incorporationof a paddle or cage fan 110 in back panel 14. In one aspect shown inFIG. 16, a rechargeable battery pack 104 is illustrated to bepositionable within accommodating slot 116 within side panel 16 ofhousing 10. Knob 106 is used to variably define the power setting usedwith battery pack 104 as well as to be used as an “on/off” switch forcontrolling the speed of fan 110. Alternatively, and in another aspectof the invention, at least one, preferably two or more rechargeable drycell batteries, 108 a , 108 b are employed within side panel 16 ofhousing 10 as better illustrated in FIG. 17. The batteries arepositioned to be loaded from the bottom of housing 10 and, the powercontrolled by a variably positioned knob 106 located toward the front ofhousing 10 or at an alternative position as is known in the art forcontrolling variable amounts of power to an electrical device. Dependingon the rotational speed of the fan desired, coupled with battery lifeexpectancy, anywhere from one to four “C” or “D” sized batteries areemployed, although it is equally envisioned that “AA” batteries may beused in some models where power consumption is envisioned to be minimalor usage infrequent and for short duration. Fan 110 has a plurality ofpaddles or inwardly extending panels for creating air movement throughrotational pivotal movement about axis 114. The fan is typically a lowervoltage fan, e.g., 3.0 volts, powered by a direct current motor. Thisincreased air flow insures maximal cooling capacity on various metal andplastic components in heater A. Battery operation is also illustrated inFIG. 26 where an alternative dry cell location is identified.

FIGS. 18-19 illustrate another embodiment of the invention in which asnap-fit door 100 is removable from side panel 18.

FIGS. 20-27 illustrate yet another embodiment of the invention in whichmore than one fuel source is positionable within the housing. Asillustrated in FIG. 20, two fuel sources 50 a , 50 b are positionedwithin side wall 18 and at least partially covered by dome-shapedshoulders, and in one aspect, completely enclosed therein as illustratedin FIG. 21. Temperature controller button 20 and igniter button 22 arepositioned similarly to that shown previously in FIG. 4.

In FIGS. 22-23, two fuel sources 50 a , 50 b which are at leastpartially enclosed by dome-shaped side panels 52 a , 52 b are positionedon opposed sides 18 , 16 of heater housing 10. In this particularembodiment, the units are connected by a mixing valve (not shown) andthe temperature controller button 20 and igniter button 22 operate tocontrol a single burner unit.

In FIGS. 24-25, two fuel sources 50 a , 50 b are once again shown, thecanisters protruding at least partially from the rear 14 of heaterhousing 10. As illustrated in this embodiment, each fuel source has itsindividual temperature controller buttons 20 a , 20 b and igniterbuttons 22 a , 22 b for controlling the temperature of heater A.

It is recognized that when dual fuel source applications are discussed,it is recognized that the heat capacity of each burner need not be thesame, and it is within the scope of this invention that differentcapacity burners are envisioned. For maximum heat control by theend-user, it is within the scope of the invention that one burner willbe for “low” capacity applications and wherein the second burner will befor “high” capacity applications, and wherein the two burners can beused in combination to produce yet a higher capacity unit. For otherapplications, there will be two “low” capacity burners employed withinone unit as well as applications where there will be two “high” capacityburners employed within the same unit. In a more expensive version ofthe heater, two continuously variable burners will be employed, suchvariability predicated by the rate at which fuel and/or air is suppliedto the burners as well as the capacity of the burners.

In the foregoing description, certain terms have been used for brevity,clearness and understanding; but no unnecessary limitations are to beimplied therefrom beyond the requirements of the prior art, because suchterms are used for descriptive purposes and are intended to be broadlyconstrued. Moreover, the description and illustration of the inventionis by way of example, and the scope of the invention is not limited tothe exact details shown or described.

While the gas-fired heater with carbon dioxide detector has beendescribed above in connection with the certain embodiments, it is to beunderstood that other embodiments may be used or modifications andadditions may be made to the described embodiments for performing thesame function of the gas-fired heater with carbon dioxide detectorwithout deviating therefrom. Further, all embodiments disclosed are notnecessarily in the alternative, as various embodiments may be combinedto provide the desired characteristics. Variations can be made by onehaving ordinary skill in the art without departing from the spirit andscope of the gas-fired heater with carbon dioxide detector. Therefore,the gas-fired heater with carbon dioxide detector should not be limitedto any single embodiment, but rather construed in breadth and scope inaccordance with the recitation of the attached claims.

1. A portable gas-fired heater comprising: a housing adapted to at leastpartially enclose a fuel source; a burner assembly enclosed by saidhousing; and a carbon dioxide detector system.
 2. The portable gas-firedinfrared heater of claim 1, wherein said burner assembly enclosed bysaid housing comprises, a gas valve adapted to receive fuel from a fuelsource; an orifice in communication with the gas valve; an air inletcommunicating with the environment; a venturi in communication with saidorifice and in communication with said air inlet, said venturi adaptedto mix air from said air inlet and fuel from said orifice into afuel-air mixture; and a combustion region adapted for the combustion ofsaid air-fuel mixture comprising, a rear face in communication with saidventuri, and a radiant surface.
 3. The portable gas-fired infraredheater of claim 2, wherein said carbon dioxide detector systemcomprises, a standing pilot; a safety valve; a PC board; and a battery.4. The portable heater of claim 3 further comprising an igniter.
 5. Theportable heater of claim 3 wherein said fuel source comprises a propanefuel tank.
 6. The portable heater of claim 5 wherein said fuel sourcecomprises at least two propane fuel tanks, wherein said propane fueltanks are completely enclosed within said housing.
 7. The portableheater of claim 3 further comprising a controller for selectivelyswitching operation states of the portable heater.
 8. The portableheater of claim 3 further comprising a regulator for reducing pressurefrom an associated fuel source.
 9. The portable heater of claim 3further comprising a fan; and a power source for said fan.
 10. Theportable heater of claim 9 wherein said power source is selected fromthe group consisting of a dry cell battery, a battery pack, andcombinations thereof.
 11. A portable gas-fired infrared heatercomprising: a housing, said housing comprising a handle adapted fortransporting the heater, and an air inlet; a regulator; a burnerassembly mounted within the housing, said burner assembly comprising afuel valve adapted to control communication with a fuel source, aventuri for mixing air from the air inlet and fuel from the fuel valveinto a fuel-air mixture; a radiant surface, said radiant surfacerecessed into the housing, disposed at an angle to vertical, andcomprising a rear face; a plenum chamber adjacent to said radiantsurface, said plenum chamber in communication with said radiant surface,and adapted to distribute said fuel-air mixture onto the rear face ofthe radiant surface; and a carbon dioxide detector system, said carbondioxide detector system adapted to shut off the fuel valve in responseto detection of a predetermined level of carbon dioxide.
 12. Theportable heater of claim 11 further comprising a control knob adaptedfor selecting various operative states of the heater.
 13. The portableheater of claim 11 further comprising an elongated hose assembly adaptedfor connecting the heater to a fuel source.
 14. The portable heater ofclaim 11, wherein said fuel source is a propane cylinder.
 15. Theportable heater of claim 11 further comprising an igniter.
 16. Theportable heater of claim 11 which further comprises a fan adapted toincrease air circulation through said heater; and a power source adaptedto power said fan, said power source comprising a member selected fromthe group consisting of a dry cell battery, a battery pack, andcombinations thereof.
 17. A portable gas-fired radiant heatercomprising: a housing; a fuel source; a fuel connection fitting; an airinlet; a burner assembly mounted within the housing, said burnerassembly comprising a fuel valve adapted to control communication withsaid fuel source a radiant surface in the housing, said radiant surfaceadapted to function as a combustion site; and an automatic shutoffmechanism operatively associated with the burner assembly for shuttingoff the fuel valve in response to a detection of a predetermined levelof carbon dioxide.
 18. The portable radiant heater of claim 17 whereinthe automatic shutoff mechanism comprises a carbon dioxide detector. 19.The portable radiant heater of claim 18 wherein the automatic shutoffmechanism shuts off at measured carbon dioxide levels at a predeterminedlevel.
 20. The portable radiant heater of claim 18 wherein the automaticshutoff mechanism shuts off at calculated oxygen levels of approximatelyat least 18%.